US11511776B2 - System and method for in-motion railcar loading - Google Patents

System and method for in-motion railcar loading Download PDF

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Publication number
US11511776B2
US11511776B2 US16/690,186 US201916690186A US11511776B2 US 11511776 B2 US11511776 B2 US 11511776B2 US 201916690186 A US201916690186 A US 201916690186A US 11511776 B2 US11511776 B2 US 11511776B2
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Prior art keywords
railcar
lid
latch
moving
coordinate system
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US16/690,186
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US20200156670A1 (en
Inventor
Martin Murray
Yu Hin Wu
William Wang
Ryan Jolivet
Volodymyr Ponomar
Matthew MacLeod
Maurizio Darini
David Henry Rudge
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Bhp Canada Inc
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BHP Billiton Canada Inc
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Assigned to BHP Billiton Canada Inc. reassignment BHP Billiton Canada Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RUDGE, DAVID HENRY, DARINI, MAURIZIO, MACLEOD, MATTHEW, Wu, Yu Hin, LeMay, Jason, WANG, WILLIAM, HEUER, TREVOR, PONOMAR, Volodymyr, MURRAY, MARTIN, BOURQUE, JEAN PASCAL, HIRSCH, CORY, JOLIVET, RYAN, MUSHTAQ, AMIR, Posnikoff, Ryan
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D39/00—Wagon or like covers; Tarpaulins; Movable or foldable roofs
    • B61D39/006—Opening and closing means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1664—Programme controls characterised by programming, planning systems for manipulators characterised by motion, path, trajectory planning
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1656—Programme controls characterised by programming, planning systems for manipulators
    • B25J9/1669—Programme controls characterised by programming, planning systems for manipulators characterised by special application, e.g. multi-arm co-operation, assembly, grasping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00—Programme-controlled manipulators
    • B25J9/16—Programme controls
    • B25J9/1679—Programme controls characterised by the tasks executed
    • B25J9/1682—Dual arm manipulator; Coordination of several manipulators
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B61—RAILWAYS
    • B61D—BODY DETAILS OR KINDS OF RAILWAY VEHICLES
    • B61D39/00—Wagon or like covers; Tarpaulins; Movable or foldable roofs
    • B61D39/006—Opening and closing means
    • B61D39/007—Controlled by trackside means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G67/00—Loading or unloading vehicles
    • B65G67/02—Loading or unloading land vehicles
    • B65G67/04—Loading land vehicles
    • B65G67/22—Loading moving vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2814/00—Indexing codes relating to loading or unloading articles or bulk materials
    • B65G2814/03—Loading or unloading means
    • B65G2814/0301—General arrangements
    • B65G2814/0302—Central control devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G2814/00—Indexing codes relating to loading or unloading articles or bulk materials
    • B65G2814/03—Loading or unloading means
    • B65G2814/0347—Loading or unloading means for cars or linked car-trains with individual load-carriers
    • B65G2814/0349—Loading or unloading means for cars or linked car-trains with individual load-carriers loading continuously successive cars without material spillage

Definitions

  • the present invention relates to systems and methods for automated operations of railcars, and more specifically to automated loading of railcars while in motion.
  • Opening and closing lids on railcars requires operators to access the tops of railcars, which involves work at heights and typically isolation mechanisms to ensure the railcars cannot move and controls to either prevent railcar motion, or at least to sufficiently control railcar motion to allow access while in motion.
  • U.S. Pat. No. 3,831,792 to Waterman et al. teaches a system for automated opening and closing of top lids on railcars, wherein a custom handle engages and runs along an overhead track during the loading process, with the track curved such that the handle causes the lid to open and close as the handle moves along the course of the overhead track.
  • This is similar to the RotoHatchTM system commercialized by the EcoFab group of companies.
  • this solution requires that every railcar lid be of the custom design to engage with the opening/closing structure.
  • a system and method for loading railcars having upper lids with latches, while the railcars are in motion through a loading facility is provided. This end can be achieved by means for locating the lid and latch and other features of each, and then employing robotic arms to unlatch, open, close and re-latch, all while the railcar is moving through a loading facility and while the velocity of the railcar is being determined and that velocity is used to guide the robotic arms.
  • a railcar operation system for performing an operation on a moving railcar in a string of railcars, where the moving railcar has a latch and a lid.
  • the system can include a sensing system for detecting a position of at least one of: the latch; and the lid, on the moving railcar, at least one velocity sensor for measuring a moving speed of the moving railcar separate from other railcars in the string of railcars, a robot arm for executing the operation on the at least one of: the latch; and the lid, and at least one controller for using a measured moving speed of the moving railcar with the position of the at least one of: the latch; and the lid, to generate commands to instruct the robot arm.
  • the robot arm in response to the commands from the at least one controller, can execute an adjusted toolpath to follow the moving railcar and to engage with the at least one of: the latch; and the lid, for performing the operation while the railcar is moving.
  • a method for performing an operation on a moving railcar in a string of railcars where the moving railcar has a latch and a lid.
  • the method can include detecting a position of at least one of: the latch; and, the lid, on the moving railcar, measuring a moving speed of the moving railcar separate from other railcars in the string of railcars, using the measured moving speed of the moving railcar and the position of the at least one of: the latch, and, the lid, to determine an adjusted toolpath, and having a robot arm execute the operation on the at least one of: the latch; and, the lid, while the railcar is moving by following the adjusted toolpath.
  • a railcar loading system for loading materials into a series of moving railcars passing through a series of stations, where each railcar has a latch and a lid.
  • the railcar loading system includes at least one sensing system for detecting positions of the latch and positions of the lid on a moving railcar relative to a railcar coordinate system, the railcar coordinate system fixed relative to the moving railcar, at least one velocity sensor for measuring a moving speed of the moving railcar, a first robot arm for performing an operation of unlatching the latch at an unlatching station, a second robot arm for performing an operation of opening the lid at a lid opening station, a loading device for performing an operation of loading materials into each moving railcar at a filling station, a third robot arm for performing an operation of closing the lid at a lid-closing station, a fourth robot arm for performing an operation of latching the latch at a latching station, and at least one controller for generating commands to instruct each robot arm for performing the corresponding operation.
  • the at least one controller can use a measured moving speed of the moving railcar and the position of at least one of: the latch, and, the lid, to determine an adjusted toolpath for each robot arm and then instruct each robot arm to follow the determined adjusted toolpath to engage with one of: the latch; and the lid, while the railcar is moving through the station to perform the robot arms corresponding operation.
  • a train of railcars is moved through a loading facility at a slow but steady rate of speed.
  • a system comprising a plurality of sensors, such as cameras, which system is thus able to identify the location of the latch and send a signal to a controller to position a first robotic arm adjacent the latch and then unlatch the latch at a first robotic arm station.
  • a second robotic arm station as the railcar continues moving through the facility, a second robotic arm opens the now-unlatched lid, and the railcar moves into a loading area where loading equipment fills the railcar interior with the specific product such as potash.
  • the still-moving railcar can enter a third station wherein a third robotic arm operates to close the lid.
  • a fourth robotic arm operates along its adjusted toolpath to engage the latch and thus secure the lid in a closed position for further transport, and the railcar exits the facility.
  • the robotic arms can be directed by a controller to enact an adjusted toolpath based on the specific function of the particular robotic arm and the location and speed of the railcar and the target latch or lid, as the case may be.
  • the instantaneous velocity of a railcar is determined by at least one velocity sensor such as a laser surface velocimeter, which velocity information is communicated to the controller to aid the robotic arm in being positioned correctly in order to execute its toolpath.
  • the combination of the system, the at least one velocity sensor and the control system works to provide the controller with information on the latch and lid location in three-dimensional space at a series of points as the railcar moves through the facility.
  • the individual railcars move at slightly differing speeds compared to adjacent railcars due to slack in the connection members, and the determination of individual railcar velocity thus enables more accurate robotic arm engagement.
  • individual railcars may be subject of slightly differing tilt and elevation during passage through the loading facility, and the combination of the system and at least one velocity sensor may allow more effective tracking of the individual railcars for the various stages of the loading process.
  • FIGS. 1 a and 1 b are top perspective views of conventional railcar lids in the opened and closed orientations
  • FIGS. 2 a and 2 b are side perspective views of conventional latches for a railcar lid
  • FIG. 3 is a schematic view of a railcar loading system
  • FIG. 4 is a perspective view of a machine vision system
  • FIG. 5 is a perspective view of a velocity sensor
  • FIG. 6 is a perspective view of a robotic arm showing the tool end positioned below the arm base;
  • FIGS. 7 a to 7 d illustrate a lid unlatching sequence
  • FIG. 7 e is an elevation view of a robotic arm unlatching a lid
  • FIGS. 8 a to 8 d illustrate a lid opening sequence
  • FIG. 8 e is an elevation view of a robotic arm opening a lid
  • FIG. 9 is an schematic view of a loading zone
  • FIGS. 10 a to 10 d illustrate a lid closing sequence
  • FIGS. 11 a to 11 d illustrate a lid latching sequence
  • FIG. 11 e is an elevation view of a robotic arm latching a lid.
  • FIG. 11 f is a perspective view of a robotic arm latching a lid.
  • a loading system that may incorporate railcars of varying lid and latch designs and account for differences from manufacturing tolerances, differing railcar position (tilt, elevation, orientation), and velocities between adjacent railcars, while reducing manpower requirements.
  • the product warehouse control system refers to the marketing system to determine when a train may arrive to be loaded and may ensure sufficient product exists, and is in a pile that has been groomed prior to train arrival at site so that the train loading process can be completed without any interruptions in loading rate.
  • the reclaimer may perform the necessary pile grooming while pre-loading the load-out surge bin.
  • product storage bins Surge and storage capacity for railcar loading systems is provided by product storage bins. These bins accept the product from the conveyances, and discharge the required amount for loading to the weigh bins.
  • the reclaiming rate from the storage building is typically controlled by the bin level to ensure a steady feed to the weigh bins.
  • the method of operation is that the product storage surge bin allows product to flow to the weigh bin continuously while weighing and dispatching take place.
  • the two-stage system allows the load to be pre-filled while the railcars are moving or the loading spout is getting into position.
  • the weigh bin is instrumented with load cells to determine when a predetermined weight has entered the bin. At the predetermined weight, a charging gate closes and a weigh bin waits to freely discharge into a railcar. The weigh bin normally empties multiple times into each railcar with the final fill as a top-up to meet a maximum allowable loading without going over and incurring rail penalties. The weights are recorded by the loading system so that the exact weight of product loaded is known.
  • a speed and positioning of the railcars may be achieved by either railcar indexers and/or railcar movers.
  • smaller strings of railcars are disconnected from the train and moved into position for loading, with the indexer holding each railcar stationary to enable loading before advancing the subsequent railcar into position.
  • An operator can then engage in the unlatching, opening, closing and latching activities from a position on top of each railcar when it is stationary.
  • a railcar mover while operating in a similar fashion to an indexer, may not be controlled from a control room and thus introduces greater risk as it requires excellent communication protocols between a railcar mover operator, a train operator, and a load-out control room operator to ensure that personnel are not on a moving railcar.
  • railcar movers may be limited to 10 to 20 cars. Some sites move larger strings using site locomotives which can handle 30 cars or more, but the general inefficiencies remain.
  • a remote locomotive control system is used to control the speed of the train, and the railcars may be loaded continuously without stopping.
  • Remote locomotive control systems such as LocotrolTM (a product of GE Transportation Systems) operate trains using distributed power (with multiple locomotives distributed throughout the train—typically two at the front, two mid-train, and one at the rear) to provide more efficient load sharing and lower coupling forces, but these systems also allow locomotives to be operated remotely from a control room and can hold the train at a fixed low speed between 0.3 and 0.5 mph. Loading the train continuously unlocks significant value since a standard train may be loaded entirely within a single 12-hour shift, such that the rail service provider may leave locomotive power connected to the train.
  • LocotrolTM a product of GE Transportation Systems
  • the rail service provider may drop railcars off at the site and then return to assemble the railcars into a full train and pull them out days later.
  • the rail service provider incurs greater cost due to additional transit time and handling, plus loss of efficiency since their power is doing less productive work. Also, the site requires much greater storage track space.
  • FIGS. 1 a and 1 b illustrate a conventional upper lid 10 in opened and closed positions
  • FIGS. 2 a and 2 b illustrate latches 12 according to a conventional latch design common in the industry, such as the IRECO 30149 latch.
  • Railcar lids have traditionally been unlatched and opened by hand, an operation which requires the operator to access the top of the railcar. Due to corrosion, latches may also be seized requiring additional effort and/or use of hammers to loosen. Ice and snow create additional obstacles and hazards on the running boards and can lead to strain-type injuries as operators attempt to pry the lids open. Lid materials have evolved to adopt fiberglass and aluminium to increase longevity while reducing weight compared to steel lids, however, the progression to longitudinal lids has increased the lid size and hence the weight, making manual operation even more difficult. As described herein, operators are not required to be on top of the railcars to manually manipulate the lids and latches, thus reducing these risks.
  • FIG. 3 illustrates a loading system 14 that automatically unlatches latches 12 on lids 10 of individual railcars 30 , so that each railcar 30 can be loaded with product before the lids 10 are automatically closed and latched.
  • each individual railcar 30 can enter a de-icing station 16 .
  • the railcars 30 of the train 28 may be assessed using an automated scanning system, such as a machine vision system, to ensure that the tops of the railcars 30 are free of snow, ice, and/or debris. If an issue is detected, a conventional de-icing system and/or brushes may be employed automatically, in response to the scanning system determination at the de-icing station 16 that there is unwanted snow, ice, and/or debris, for clearing the upper surfaces of a railcar 30 before the railcar 30 enters the loading system 14 .
  • FIG. 3 illustrates the various stations of the loading system 14 .
  • These stations can include: a first stage having an unlatching station 18 where a robot unlatches the latches 12 on the lid 10 of a railcar 30 ; a second stage having a lid opening station 20 where the lid 10 of a railcar 30 is opened after the latch 12 is unlatched; a filling station 22 , where product is loaded into the railcar 30 ; a third stage having a lid-closing station 24 where the lid 10 of the railcar 10 is once again closed; and a fourth stage having a latching station 26 where the latch 12 on the lid 10 of the railcar 30 is one again latched.
  • each railcar 30 passes through each station in turn as the train 28 moves continuously through the loading system 14 .
  • Each robotic arm 34 may be provided with task-specific tooling to handle its intended task.
  • a first sensing system 32 a may be employed to locate the lid 10 and the latch 12 .
  • FIG. 4 illustrates a sensing system 32 , which could be used as first sensing system 32 a .
  • the sensing system 32 may be a machine vision system comprising a plurality of sensors, such as cameras, scanners, radar, etc. Various alternatives to the use of cameras may be used, such as laser profilometers or radar systems. In some aspects, more than 2 cameras may be employed.
  • One or more sensors 33 can be positioned horizontally to aim in a first direction, aiming downwards towards a top of a railcar 30 passing by the sensing system 32
  • one or more sensors 35 can be positioned vertically, and directed approximately 90° to the direction of the horizontally positioned one or more sensors 33 , to aim towards a side of a railcar 30 .
  • the sensing system 32 can identify the location of the latch 12 and/or a lid 10 on a railcar 30 passing by the sensing system 32 .
  • One sensor such as one of the horizontally positioned sensor 33 , may search for the closed latch 12 on both sides of the railcar 30 to detect which side of the lid 19 the latch 12 is positioned on.
  • Some sensors may locate the coordinate positions of the latch 12 along an axis parallel to the track (the X axis), such as the horizontally positioned sensors 33 , and a vertical axis (the Z axis), such as the vertically positioned sensors 35 , while other sensors, such as the horizontally positioned sensors 33 , may determine the coordinate position of the latch 12 along a transvers axis to X (the Y axis).
  • This X, Y and Z coordinate can be defined as the railcar coordinate system and fixed relative to the specific railcar 30 .
  • the sensors can then work together to search for the lid 10 edges and calculate the railcar 30 tilt angle using trigonometry.
  • the determined coordinates of the latch 12 in the railcar coordinate system is fixed relative to the individual railcar 30 so that the latch 12 always remains in the same location in the railcar coordinate system even as the railcar 30 moves along the track because the railcar coordinate system will move with the railcar 30 .
  • One skilled in the art may upon review of the present disclosure understand that alternative sensing systems may be employed providing the same or similar functionality.
  • a new railcar coordinate system can be created for each railcar 30 with the position/coordinates of the latch(es) 12 on that railcar 30 determined in its railcar coordinate system.
  • the latches 12 on each railcar 30 will be located by the first sensing system 32 a and their position in a railcar coordinate system that is fixed to each railcar 30 determined.
  • the first sensing system 32 a may search one or more captured images for key features against pre-defined models, such as searching for three key edges (one parallel to each of the Cartesian directions) to determine the position of the latches 12 in the railcar coordinate system.
  • the sensing system 32 a may identify the location of the latch 12 and determine its position in a railcar coordinate system that is fixed in relation to the railcar 30 .
  • the sensing system 32 a can then synchronize with and communicate the position information to a controller (not shown), which in turn directs a robotic arms 34 in the unlatching station 18 to position itself according to this position and orientation information of the latch 12 so that the robotic arm 34 can unlatch the latch 12 on the railcar 30 .
  • Velocity sensors 36 such as laser surface velocimeters, as illustrated in FIG. 5 , can be employed to measure the instantaneous velocity or moving speed of each individual railcar 30 .
  • the sensing system 32 locates where the latch 12 or lid 10 is on each railcar 30 in 3D space at a given time and can determine the position of the latch 12 in railcar coordinate system fixed to the individual railcar 30 . This position information of the latch 12 can then be used so that the robotic arm 34 can be engaged with the latch 12 or lid 10 and execute an adjusted toolpath for the tooling.
  • the velocity sensor 36 can continue to track the latch 12 or lid 10 until it reaches a synchronization point, and when the synchronization point is reached, a synchronization signal can then be sent to the controller. From the moment of synchronization, the controller may r the instantaneous velocity signal from the velocity sensor 36 in order to determine the position of the railcar 30 along the tracks. Determining the position of the railcar 30 will thereby determine the position of the railcar coordinate system which is fixed in relation to the railcar 30 .
  • These coordinates of a latch 12 on the railcar 30 in the railcar coordinate system can be sent to the controller for the robot arm 34 in the unlatching station 18 , where this information can be used to position a latch/lid coordinate system fixed relative to the robot arm 34 in the unlatching station 18 and offset relative to the moving railcar coordinate system fixed relative to the moving railcar 30 .
  • This can allow the robotic arm 34 to execute an adjusted toolpath where the coordinates of the latch 12 in the moving railcar coordinate system and the measured velocity of the specific railcar 30 can be resolved with the latch/lid coordinate system fixed relative to the robotic arm 34 so that the robotic arm 34 can execute the adjusted toolpath in the latch/lid coordinate system and thereby follow along with railcar 30 as it moves through the system and specifically the latch 12 on the railcar 30 .
  • the robotic arm 34 can follow the adjusted toolpath and move along with the latch 12 on the railcar 30 allowing the robotic arm 34 to unlatch the latch 12 as the railcar 30 moves dynamically along the tracks.
  • FIGS. 7 a to 7 d an unlatching process at the unlatching station 18 is illustrated; note that the Figures are taken from operation of a prototype that was constructed to test the system, and thus only the lids and latches are shown rather than whole railcars.
  • the robotic arm 34 with unlatching tooling 42 is in the standby position, but near the latch 12 . Having passed the first sensing system 32 a , which side the closed latch 12 is on will be known, thus enabling the robotic arm 34 to position itself on the correct side to engage the latch 12 .
  • the robotic arm 34 can be directed to follow the adjusted toolpath so that the robotic arm 34 can move adjacent to the latch 12 and move along with the latch 12 as the railcar 30 moves through the unlatching station 18 .
  • FIG. 7 b shows the robotic arm 34 engaging the unlatching tooling 42 with the thumb trigger of the latch 12 , as shown in FIG. 7 b .
  • FIG. 7 c shows the unlatching tooling 42 being used to lift the latch 12 handle while keeping the thumb trigger engaged
  • FIG. 7 d shows the latch 12 handle continuing to be rotated until open.
  • the latch 12 is now disengaged and the railcar 30 can move into the lid opening station 20 .
  • each robotic arm 34 there may be multiple velocity sensors 36 for each robotic arm 34 to provide a redundant and/or continuous velocity signal of each railcar 30 .
  • each robotic arm 34 may comprise a base 38 and a tool arm 40 , the latter for supporting the task-specific tooling.
  • the robotic arm 34 allows for the base 38 to be positioned above the railcar 30 passageway, while the tool arm 40 can extend downwardly to engage the lid 10 or latch 12 , as the case may be.
  • the railcar 30 can enter the second stage with the lid opening station 20 .
  • the steps performed in the lid opening station 20 are illustrated.
  • the railcar 30 passes the second sensing system 32 b , the coordinates of the lid 10 and the edges of the lid 10 can be determined in the railcar coordinate system and the railcar 30 tilt and a velocity sensor 36 can measure the speed of the railcar 30 .
  • These coordinates of the lid 10 on the railcar 30 in the railcar coordinate system and the measured velocity of the railcar 30 can be sent to the controller for the robot arm 34 in the lid opening station 20 , where this information can be used to position a latch/lid coordinate system fixed relative to the robot arm 34 in the lid opening station 20 and offset relative to the moving railcar coordinate system fixed relative to the moving railcar 30 .
  • This can allow the robotic arm 34 to execute an adjusted toolpath and move along with the moving lid 10 so that the robotic arm 34 can open the lid 10 on the railcar 30 .
  • the robotic arm 34 can move into position to engage the edge of the lid 10 with tooling 44 .
  • the robotic arm 34 can rotate the tooling 44 to clear any rubber seal while following the adjusted toolpath, and
  • FIG. 8 c shows the robotic arm 34 continuing to open the lid 10 while following the adjusted toolpath.
  • FIG. 8 d shows the robotic arm 34 being used to push against the underside of the lid 10 to push it into the fully opened position.
  • FIG. 8 e illustrates an alternative embodiment in which lid opening tooling 46 engages a lip 48 on the upper surface of the lid 10 , and thus the tooling 46 remains engaged with the lip 48 throughout opening of the lid 10 .
  • the railcar 30 interior may be exposed and ready for filling with product, and the railcar 30 moves into the loading or filling station 22 .
  • the railcar 30 interior may be first scanned to confirm that all lids have been opened and the bottom gates are closed.
  • the interior of the railcar 30 can also be scanned to ensure the interior is clean and empty before the railcar 30 is loaded with product.
  • the scanning may use a number of different techniques, such as radar scanning which can occur even before the railcar 30 enters the filling or loading stations.
  • the filling station 22 is shown.
  • Product is introduced into a surge bin 52 before passing through a charging gate 54 into a weigh bin 56 .
  • the weigh bin 56 may be instrumented with load cells 58 .
  • a discharge gate 60 may allow for product to move downwardly from the weigh bin 58 into the loading chute or filling spout 62 .
  • the filling spout 62 may be telescopic and lowers into the railcar 30 and deposits pre-weighed discharges of product into the railcar 30 interior, filling each railcar 30 to a set capacity. Note that the filling spout 62 does not move with the railcar 30 , but rather discharges the material into the longitudinal opening at the top of the railcar 30 as the railcar 30 passes through the loading or filling station 22 .
  • FIGS. 10 a to 10 d illustrate stages of the lid-closing procedure.
  • a third sensing system 32 c may be located at this station. As the railcar 30 passes by the third sensing system 32 c , sensors, such as cameras, in the third sensing system 32 c can scan the railcar 30 for a physical indicator, e.g., the tongue of an open lid 10 , to determine the location or coordinates of the lid 10 in the railcar coordinate system, and a velocity of the individual railcar 30 can be measured by a velocity sensor 36 . The third sensing system 32 may also determine which direct the lid 10 closes.
  • a physical indicator e.g., the tongue of an open lid 10
  • These coordinates of the lid 10 on the railcar 30 in the railcar coordinate system and the measured velocity of the railcar 30 can be sent to the controller for the robot arm 34 in the lid-closing station 24 , where this information, along with the measured velocity of the railcar 30 , can be used to position a latch/lid coordinate system fixed relative to the robot arm 34 in the lid-closing station 24 and offset relative to the moving railcar coordinate system fixed relative to the moving railcar 30 .
  • the latch/lid coordinate system tracks the motion of the railcar 30 (via the velocity sensors 36 )
  • the robotic arm 34 with task-specific tooling 64 moves into standby position as shown in FIG. 10 a .
  • the robotic arm 34 can follow the adjusted toolpath, moving the tooling 64 adjacent to the moving lid 10 , and the tooling 64 on the robotic arm 34 can engage the underside of the opened lid 10 as shown in FIG. 10 b .
  • continued upward movement of the tooling 64 rotates the lid 10 until the lid 10 begins moving downwardly as shown in FIG. 10 d toward a closed orientation.
  • FIGS. 11 a to 11 f a latching procedure is illustrated.
  • sensors, such as cameras, in the fourth sensing system 32 d can scan the railcar 30 for which side of the railcar 30 the latch 12 is placed on and the position of the latch 12 on the railcar 30 .
  • the sensors of the fourth sensing system 32 d may be used to determine the X, Y and Z coordinates of the latch 12 on the lid 10 , and the sensors can be used together to locate the lid 10 edges and determine a tilt of the railcar 30 . Using this location information, the sensors in the fourth sensing system 32 d can be used to determine the location or coordinates of the latch 12 and/or the lid 10 in the railcar coordinate system.
  • These coordinates of the latch 12 and/or the lid 10 on the railcar 30 in the railcar coordinate system can be sent to the controller for the robot arm 34 in the latching station 26 , where this information can be used to position a latch/lid coordinate system fixed relative to the robot arm 34 in the latching station 26 and offset relative to the moving railcar coordinate system fixed relative to the moving railcar 30 .
  • the robotic arm 34 can follow the adjusted toolpath, moving along with the moving latch 12 , and tooling 66 on the robotic arm 34 can re-latch the latch 12 securing the lid 10 on the railcar 30 closed once again.
  • the specific type of tooling and the requisite toolpath programming may be determined by the latch or lid that is present on a railcar, and the sensing system 32 a may be programmed with the various latch types so that the sensing system 32 can recognize the particular latch, identify a suitable tool, and execute the correct toolpath. If a train is going to arrive that has railcars with two different latch or lid types requiring two different tooling types, for example, a number of robotic arms could be employed, each with the tooling appropriate to one of the incoming latch or lid types, they could be deployed accordingly once the sensing system detects the latch or lid type. In some aspects, standardization in latch or lid type may simplify the tooling selection.
  • tooling may engage with more than one style of lid or latch, but with a differing toolpath for each lid/latch type.
  • the robotic arm may have a variety of tools from which can select based on the incoming lid/latch, and a coupling such as a quick-release mechanism to enable engagement of the robotic arm with the selected tool as the railcar approaches the station.
  • a component e.g. a circuit, module, assembly, device, etc.
  • reference to that component should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Robotics (AREA)
  • Transportation (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Control Of Position, Course, Altitude, Or Attitude Of Moving Bodies (AREA)
  • Power-Operated Mechanisms For Wings (AREA)
  • Manipulator (AREA)
  • Train Traffic Observation, Control, And Security (AREA)
US16/690,186 2018-11-21 2019-11-21 System and method for in-motion railcar loading Active 2041-06-10 US11511776B2 (en)

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US16/690,186 US11511776B2 (en) 2018-11-21 2019-11-21 System and method for in-motion railcar loading

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US201862770230P 2018-11-21 2018-11-21
US16/690,186 US11511776B2 (en) 2018-11-21 2019-11-21 System and method for in-motion railcar loading

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Publication number Priority date Publication date Assignee Title
US11975747B2 (en) 2021-03-30 2024-05-07 Rayhawk Technologies Inc. Bridge crane apparatus for opening and closing railcar lids

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CA3062052C (fr) 2023-09-19
CA3062052A1 (fr) 2020-05-21
WO2020102903A1 (fr) 2020-05-28
US20200156670A1 (en) 2020-05-21

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